Water conditioner rotary valve drive system

ABSTRACT

A water conditioner rotary valve for use in a water conditioning system includes a valve body constructed of an upper section, a lower section and a middle section, to facilitate ease in assembly of the body. The valve rotor member of the conditioner valve is driven by a Geneva drive system, to provide accurate positioning of the rotor member in its various positions. A valve seat member is located adjacent the rotor member, and provides a construction which improves the seal between the rotor member and the surface of the valve body adjacent thereto. The three-piece assembly of the valve body facilitates providing a valve capable of either upflow or downflow brining by replacing the lower valve section. A brine injector valve is mounted exteriorly of the valve body.

CROSS-REFERENCE TO RELATED APPLICATION

This application is a division of application Ser. No. 07/606,508, filedOct. 31, 1990, now U.S. Pat. No. 5,174,337, dated Dec. 29, 1992.

BACKGROUND AND SUMMARY

This invention relates to a rotary valve for a water conditioner, andmore particularly to a rotary valve incorporating features providing alower cost of manufacture and increased performance capabilities.

A rotary valve is typically utilized in a water conditioning system tocontrol an automatic water softener which includes a mineral bed whichis periodically backwashed and then regenerated with brine supplied froma brine tank.

It is known to provide a rotary valve for placement at the open upperend of the mineral tank of the water softener. The valve functions inconjunction with the brine tank to selectively place the system into aservice mode, a backwash mode, a brine/slow rinse mode and a fastrinse/brine tank refill mode.

One such valve assembly is disclosed in U.S. Pat. No. 4,632,150 toGagas, owned by the same assignee as the present application. The valvestructure disclosed in this patent has been found to providesatisfactory operation. However, the valve disclosed in this patent hasa relatively high cost of manufacture, in that several gluing operationsmust take place in assembling the various components of the valve.

The present invention has as its object to provide a rotary valvestructure for a water conditioning system of simple and efficientdesign, providing a reduced cost of manufacture while increasing theperformance capabilities and overall life of the valve structure.Another object of the invention is to provide a valve structure which iseasily and cheaply adaptable to various use environments.

In accordance with the invention, a rotary valve adapted for mounting tothe open top of a mineral tank comprises a valve body formed from anupper section, a lower section, and a middle section. The sections aremounted to each other such that the lower surface of the upper sectionis disposed against the upper surface of the middle section, and theupper surface of the lower section is disposed against the lower surfaceof the middle section. Each section includes one or more flow passageswhich communicate with each other when the sections are assembled todefine a water flow path having an external inlet, an outlet into thetank, an inlet from the tank, and an external outlet. A ported rotormember is disposed between two of the valve body sections forcontrolling the flow of water through the passages formed in thesections. The ports in the rotor member open onto a surface adapted forplacement adjacent to a surface of the valve middle section. A drivesystem is provided for selectively rotating the rotor member within thevalve body to selectively place the passages in the valve body sectionsin communication with each other to control the flow path of waterthrough the valve body.

In accordance with another aspect of the invention, an improved drivesystem is provided for imparting rotation to the rotor member of arotary valve. The drive system comprises spaced Geneva cam surfaces onthe rotor member, and a Geneva drive shaft engagable with the camsurfaces and movably mounted to the valve body. Drive means selectivelyimparts rotation to the Geneva drive shaft. The Geneva drive system forthe rotor member eliminates inaccuracies introduced by prior art drivesystems which typically comprised a rotating worm gear engagable with aworm wheel, or a pinion gear engagable with a spur gear.

The valve body can be assembled for either an upflow brining applicationor a downflow brining application. The upper and middle sections of thevalve body have flow passages arranged so as to be usable in eitherapplication. Either an upflow or a downflow lower section is assembledto the upper and middle sections, depending on the application for theparticular valve being assembled. In this manner, the valve body cancheaply and easily be adapted for use in either application.

A brine valve assembly is mounted to the exterior of the valve body. Thebrine valve is preferably assembled to the valve body middle section,which facilitates adaptability of the valve to either an upflow briningapplication or a downflow brining application.

In accordance with another aspect of the invention, an improvedstructure is provided for a valve seat disposed between the lowersurface of the rotor member and a surface of the valve body adjacentthereto. The valve seat member is constructed of an annular stiffeningmember surrounded by a thermoplastic elastomeric material. Thestiffening member is preferably in the form of a ring. The elastomericmaterial is formed around the stiffening ring so as to provide openingsextending between opposite surfaces of the valve seat member. Theelastomeric material is formed so as to provide rib structures on bothsides of the valve seat member surrounding the openings to provide afluid-tight seal between the rotor member and the surface of the valvebody adjacent thereto.

In accordance with another aspect of the invention, structure isprovided on the valve body for blending hard water from the inlet of thevalve into the conditioned water, at the option of the operator. Aninlet cavity is preferably formed in the valve body upper section forreceiving intake hard water. A lug having a vertical passage is formedon the upper section adjacent a wall forming the inlet cavity. A treatedwater outlet is preferably formed in the valve body middle section, andthe vertical passage is located over the treated water outlet. When hardwater blending is desired, an opening is formed between the verticalpassage and the hard water inlet cavity, and an opening is formedbetween the lower end of the vertical passage and the treated wateroutlet. A manually adjustable bonnett valve is placed in the verticalpassage, to control the amount of hard water flowing from the inletcavity to the treated water outlet.

In accordance with yet another aspect of the invention, an improvedbypass valve structure is provided for controlling whether hard water issupplied to the inlet of the conditioner valve body or bypassed aroundthe conditioner valve directly to the outlet. The bypass valve includesa valve body having an inlet passage and an outlet passage, and inletand outlet ports. The bypass valve body is adapted for connection to theconditioner valve body such that the bypass valve inlet and outlet portscommunicate with the inlet and outlet, respectively, of the conditionervalve. The bypass valve inlet passage and outlet passages are alignedwith the inlet and outlet ports, respectively, and a spool passage isdisposed therebetween. A spool member is disposed within the spoolpassage, and includes flow diverting structure which, when the spoolmember is in its bypass position, directs water directly from the bypassvalve inlet passage to the bypass valve outlet passage through the spoolpassage. In its operating position, the flow diverting structure cutsoff communication between the bypass valve inlet passage and its outletpassage, and diverts water from the inlet passage to the inlet of theconditioner valve.

Other objects, features and advantages of the invention will becomeapparent in view of the following description of the preferredembodiment of the invention taken together with the drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

The drawings illustrate the best mode presently contemplated of carryingout the invention.

In the drawings:

FIG. 1 is a partial isometric view showing a valve constructed accordingto the invention mounted to the upper end of a mineral tank, with thecover and control components of the valve shown in exploded fashion;

FIG. 2 is an exploded isometric view showing the various components ofthe valve of FIG. 1;

FIG. 3 is a schematic cross-sectional view through the assembled valveof FIG. 1, showing a valve lower section providing upflow brining;

FIG. 4 is a schematic partial sectional view showing an alternateconstruction for the lower section of the valve of FIG. 3, providingdownflow brining;

FIG. 5 is a top plan view of the valve of FIG. 1;

FIG. 6 is an enlarged partial top plan view of a portion of the valveshown in FIG. 5, with portions removed;

FIG. 7 is a top plan view of the valve of FIG. 5 with its too sectionremoved, showing the rotor member in plan and the Geneva drive shaftengagable therewith;

FIG. 8 is a bottom plan view of the valve rotor member;

FIG. 9 is a partial top sectional view showing the brine valve injectorsystem for routing brine from the brine tank to the mineral bed;

FIG. 10 is a sectional view of the brine valve system of FIG. 9 takengenerally along line 10--10 of FIG. 9;

FIGS. 11-14 are top plan views of the valve seat member, showing inphantom the position of the rotor member ports relative to the openingsof the valve seat member;

FIG. 15 is a top plan view of the valve seat member of FIGS. 11-14, witha portion broken away;

FIG. 16 is a bottom plan view of the valve seat member of FIG. 15;

FIG. 17 is a partial sectional view taken generally along line 17--17 ofFIG. 16;

FIG. 18 is a partial sectional view taken generally along line 18--18 ofFIG. 16;

FIG. 19 is a top plan view showing the valve assembly of FIG. 1 with abypass valve constructed according to the invention connected thereto,with portions of the bypass valve broken away;

FIG. 20 is a section view taken generally along line 20--20 of FIG. 19;and

FIG. 21 is a partial isometric view showing a flow diverter memberassociated with the spool assembly of the bypass valve of FIG. 17.

DESCRIPTION OF THE PREFERRED EMBODIMENT

Referring to FIG. 1, a valve assembly 20 is shown mounted to the openupper end of a mineral tank 22 forming a part of a water conditioningsystem, as is known. Valve 20 is covered by a shroud assembly consistinggenerally of a lower portion 24 adapted for connection to valve 20, anupper portion 26 adapted for connection to lower portion 24, and a frontplate 28. A control board 30 is adapted for positioning behind a plate32, which contains a window 34 through which a visual read-out screen 36of control board 30 is visible. A series of actuator buttons shown at 38are accessible by an operator through openings formed in plate 32, forsetting the functions of valve 20.

Control board 30 comprises a standard electrical circuit board to whicha series of resistors, capacitors and microprocessors are mounted forcontrolling the operation of valve 20, in a manner as is known.

Referring to FIG. 2, valve 20 generally comprises an upper section 38, amiddle section 40 and a lower section 42. Generally speaking, sections38, 40 and 42 are adapted to be secured together to form valve assembly20 by use of bolts, such as shown at 44, extending through openingsformed in each valve section and engagable with nuts secured to lowersection 42 in openings formed therein.

Upper section 38 has a substantially flat annular lower surface which isadapted for placement onto an annular flat upper surface of middlesection 40, shown at 46. Similarly, a flat lower surface of middlesection 40 is adapted for placement against a substantially flat annularupper surface 48 of lower section 42. An o-ring 50 is placed betweenupper section 38 and middle section 40, and a gasket 52 is placedbetween middle section 40 and lower section 42, for providing afluid-tight seal between sections 38, 40 and 42 when assembled andsecured together.

Lower section 42 includes a series of external threads 54 which engageinternal threads formed in the open upper end of tank 22 for mountingthe assembled valve 20 to tank 22, as shown in FIG. 1. An o-ring 56provides a fluid-tight seal. The lower end of lower section 42 includesan inner annular hub 57, which is adapted to receive the upper end of astand pipe (not shown in FIG. 2) which extends downwardly into theinterior of tank 22.

Middle section 40 includes a fluid inlet port 58 for receiving hardwater from a plumbing system, and a fluid outlet port 59 for returningtreated water to the plumbing system.

A cavity is formed in the underside of valve upper section 38, and arotor member 60 is adapted to be received into the cavity. Rotor member60 generally includes a plate-like lower portion 62, a central portionproviding a series of circumferentially-spaced cam surfaces 64, and anupstanding stem 66. Stem 66 is placed into an upwardly extending recessassociated with the cavity formed in the underside of valve uppersection 38, into which rotor member 60 is placed.

Stem 66 includes a central passage 68 which, when rotor member 60 isplaced into the cavity in valve upper section 38, communicates with adrain outlet 70 formed in upper section 38. An o-ring 72 provides afluid-tight seal to communication between passage 68 and drain outlet70.

When the lower annular surface of valve upper section 38 is positionedagainst upper surface 46 of valve middle section 40, the lower surfaceof plate-like lower portion 62 of rotor member 60 bears against theupper surface of a valve seat member 74. The lower surface of valve seatmember 74 bears against the upwardly facing internal surface 7 of valvemiddle section 40. A series of washers 76, 78 and 80 are positioned overrotor member stem 66 and are disposed between the upwardly facingsurface provided by cam surfaces 64 and the downwardly facing surfaceforming the upper end of the cavity in the underside of valve uppersection 38. Washer 78 is a wave spring-type washer which acts to biasrotor member 60 downwardly toward valve middle section 40 when valvesections 38, 40 and 42 are assembled together.

Lower valve section 42 is provided with a central passage 82. A floatvalve 84 is adapted for placement into seating structure formed at theupper end of passage 82. The upper end of float valve 84 is receivedinto a recess formed in the underside of valve middle section 40 whensections 40 and 42 are assembled together.

An umbrella-type diaphragm check valve, consisting of a valve seat 88and a diaphragm 90, is placed into the upper end of a passage 92 formedin valve lower section 42.

A series of ports and passages are formed in rotor member 60 and valvesections 38, 40 and 42 for providing flow of water through valve 20 inan appropriate path according to the operational mode in which valve 20is placed. The water flow paths defined by rotor member 60 and thepassages in valve sections 38, 40 and 42 will later be explained.

Referring still to FIG. 2, a Geneva drive shaft 94 is rotatably mountedin a passage formed in valve upper section 38. Drive shaft 94 isprovided with a lower plate 96 having a pair of depending drive lugs 98,100. A drive assembly 102 consisting generally of a motor 104 and a gearbox 106, and including a depending output shaft 108, is adapted formounting to the upper surface of valve upper section 38. Output shaft108 is drivingly engagable with a passage 110 formed in the upper end ofGeneva drive shaft 94.

Also mounted to the upper surface of valve upper section 38 are arotatable actuator member 112 and a switch 114, which will later beexplained in greater detail.

A brine valve assembly 116 is located exteriorly of valve middle section40 and is connected to valve middle section 40. Brine valve assembly 116includes a brine valve body 118 having a brine inlet nipple 120. Aninjector member 124 is adapted for placement partially into a passage126 formed in the side of valve middle section 40, and partially into apassage formed in brine valve body 118 which alignment with passage 126.A fluid connector member 128 is adapted for placement partially into apassage 130 in the side of valve middle section 40, and partially into arecess in the rear surface of brine valve body 118. A brine refillcontrol plug 131 is adapted for placement partially into a passage 132in the side of valve middle section 40, and partially into a recess inthe rear surface of brine valve body 118. An umbrella-type checkdiaphragm 134 is placed in an opening in the rear surface of brine valvebody 118. An integral check seat 153 (FIG. 3) is formed in the rearsurface of body 118, and a forwardly disposed extension of check seat153 is engaged.

Referring again to FIG. 2, a brine shuttle assembly is adapted forplacement into a passage 137 formed in a brine valve body 118, whichintersects the brine inlet passage formed in brine inlet nipple 120. Thebrine shuttle assembly consists of a shaft 138 having a head 139aconnected at one of its ends, and a seat member 139b adapted forconnection to the other end of shaft 138 within passage 137, as will beexplained. A brine check assembly consisting of a ball 139c and a seat139d are adapted for placement into the brine inlet passage formed inbrine inlet nipple 120. Shaft 138 of the brine shuttle assembly extendsbetween the legs of check valve seat 139d, as will later be explained.

A brine valve cap member 139e is adapted for mounting to the end ofbrine valve body 118 to seal the passage formed therein and to placeselected passages in fluid communication with each other, as will beexplained. A pair of o-rings 139f and 139g are placed between cap member139e and brine valve body 118 to ensure a fluid-tight seal.

FIG. 3 illustrates in schematic form a section through valve assembly20. It is understood that the section view represented in FIG. 3 is forthe purpose of schematically illustrating the flow path of water throughvalve 20, and does not represent an accurate cross-section through valve20.

Referring to FIG. 3, when valve upper section 38 is assembled to valvemiddle section 40, hard water introduced into valve 20 through inlet 58(FIG. 2, not shown in FIG. 3) first flows into inlet cavity 140 formedin valve upper section 38, and in which rotor member 60 is located.Rotor member 60 and valve seat member 74 act to control the flow path ofwater from inlet cavity 140 into valve middle section 40.

FIG. 3 illustrates a normal service position in which inlet hard wateris routed through passages in rotor member 60 and valve seat member 74from inlet cavity 140 to a passage 142 formed in valve middle section 40and a passage 144 formed in valve lower section 42 and downwardly intothe mineral tank. Treated water flows upwardly from the mineral tankthrough the stand pipe, shown at 145, and into passage 82 formed invalve lower section 42. This upward flow of water through passage 82unseats float valve 84, allowing flow of water into a passage 147 invalve middle section 40 and to an outlet passage 148 through a passage149, and to the outlet 59 of valve 20. Water flowing through passage 92in valve lower section 42 is prevented from entering valve middlesection 40 by a diaphragm-type check valve assembly consisting of valveseat 88 and diaphragm 90. Similarly, water flowing through a brinerefill passage 150 in valve lower section 42 is prevented from enteringbrine valve 116 by diaphragm 134 seating against a valve seat member 153located at the entrance into a passage 154 associated with brine valve116.

A passage 155a is formed in valve middle section 40 and communicatesbetween treated water passage 147 and passage 132 (FIG. 2). Passage 155ais physically an internal passage in valve middle section 40, but forclarity is shown in FIG. 3 as a phantom line. Passage 132 communicatestreated water pressure to passage 137 through a passage 155b (FIG. 2)formed in brine valve body 118, and a space 155c which is sealed bybrine valve cap member 139e when brine valve 116 is assembled. Thetreated water pressure in passage 137 (FIG. 3) acts on brine shuttleassembly head 139a to move the brine shuttle assembly to a closedposition, as will later be explained.

To backwash the mineral bed, rotor member 60 is moved to a position inwhich communication is established between inlet cavity 140 and apassage 155 in valve middle section 40, and communication is alsoestablished between passage 149 and inlet cavity 140. When this occurs,float valve 84 is moved to its closed position, and intake hard waterfrom inlet cavity 140 is routed directly from passage 149 to outletpassage 148, thereby bypassing tank 22. Water pressure in passage 155forces diaphragm 90 away from seat 88 to provide water flow throughpassage 92 and downwardly through passage 82. This intake water is thenrouted downwardly through stand pipe 145 and into the mineral bed, andwater from the mineral bed flows upwardly through tank 22 to passage 144in valve lower section 42 and to passage 142 in valve middle section 40.In the backwash position, rotor member 60 and seal plate 74 establishcommunication between the upper end of passage 142 and drain passage 68formed in rotor member stem 66, allowing discharge of the backwash waterfrom valve 20 through drain outlet 70.

In a brine/slow rinse position, rotor member 60 is moved to a positionin which communication is established between inlet cavity 140 and theupper end of passage 162 in valve middle section 40, as well asmaintaining communication between cavity 140 and passage 149. Drainpassage 68 is placed into communication with passages 142 and 155.Intake water again flows from inlet cavity 140 through passages 149 and148 to outlet 59, bypassing tank 22. Pressure in passage 147 maintainsfloat valve 84 in its closed position. In this position, water pressureis provided to injector member 124, which creates a vacuum at area 164to draw brine in through brine inlet 120 from the brine tank. Thisprovides flow of mixed intake water and brine through passage 154 pastdiaphragm 134, and through a passage 163 to passage 150 in valve lowersection 42 and to passage 82 and downwardly through stand pipe 145. Thisregenerates the mineral bed in tank 22. Excess water from the mineralbed is flushed upwardly through the tank 22 to passage 144 throughpassage 142 in valve middle section 40 and through valve seat member 74and rotor member 60 to drain passage 68 to drain outlet 70.

In a fast rinse/refill position, rotor member 60 is moved to a positionin which communication is established between inlet cavity 140 and theupper end of a passage 168 formed in valve middle section 40.Communication is also established between drain passage 68 and the upperend of passages 149 and 155. In this position, intake water passesdownwardly through passage 168 past a diaphragm check valve 169 to apassage 170 formed in valve lower section 42, and downwardly into themineral bed. The water is thus treated, and the treated water then flowsupwardly through standpipe 145 into passage 82 in valve lower section42. The treated water then flows from passage 82 to unseat float valve84, and flows into passage 147. It then is discharged through passage149 to discharge passage 68 and to drain outlet 70. The treated water isalso available for service through outlet passage 148 and outlet 59.

Also in the fast rinse/refill position, intake water pressure issupplied to passage 130, which is in communication with the upper end ofpassage 168 in valve middle section 40. Water pressure in passage 130acts on the seat of the brine shuttle assembly, as will be explained, tomove the brine shuttle assembly to its open position. In its openposition, the brine shuttle assembly allows treated water to flow frompassages 155a and 137 past the brine shuttle head and into the passagein brine inlet nipple 120, to refill the brine tank with treated water.After the fast rinse/refill mode is completed, communication betweeninlet cavity and passage 130 is cut off and fluid pressure in passage137 forces the brine shuttle assembly to its closed position, thuscutting off flow of treated water into the brine tank.

In the positions described above and with the valve structure asillustrated in FIG. 3, the brining operation occurs with brine solutionpassing downwardly through standpipe 145, forcing water from the mineralbed to flow upwardly through the tank. This mode of operation is knownas "upflow" brining. In some use environments, it is desirable toprovide "downflow" brining, in which the brine solution flows downwardlythrough the mineral bed to force water from the mineral bed upwardlythrough the standpipe. In the past, it has been necessary to provide acompletely different valve structure in a downflow brining environmentthan in an upflow brining environment. With the present invention,however, it is only necessary to modify valve lower section 42 andreplace rotor member 60, to achieve downflow brining. As illustrated inFIG. 4, a lower valve section 172 is installed in valve assembly 20 inplace of the lower valve section 42 illustrated in FIG. 3. Like valvelower section 42, lower section 172 includes a riser insert 57 adaptedto receive the upper end of standpipe 145. The upper end of standpipe145 is in communication with a passage 174, which communicates withpassage 147 in middle valve section 40. A passage 176 extends betweenpassage 174 and passage 155 formed in valve middle section 40. A passage178 extends between passage 142 in valve middle section 40 and the upperend of the tank. A passage 180 extends between passage 168 in valvemiddle section 40 and the upper end of the tank, and a diaphragm typecheck valve assembly 181 is disposed between the upper end of passage180 and the lower end of passage 168. A passage 182 extends betweenpassage 163 in valve middle section 40 and the upper end of the tank.

With valve lower section 172 installed in valve assembly 20 in place oflower valve section 142, the service, backwash modes are substantiallyidentical in flow as described previously. However, in the brine/slowrinse mode brine introduced through the brine valve 116 passesdownwardly through passage 182 into the tank and through the mineralbed. Excess water then flows upwardly through standpipe 145 and intopassage 174, through passage 176 and upwardly through passage 155 todrain passage 68. In the fast rinse/refill position, the same flow takesplace without drawing brine, and additional intake water is introducedthrough passage 168 and past check valve assembly 181 at the upper endof passage 180, and downwardly through passage 180 into the tank.

As will later be explained, rotor member 60 has a slightly differentparting arrangement for downflow brining than for upflow brining.

Referring to FIGS. 2 and 3, an optional hardwater blending system can beincorporated into valve assembly 20 by use of a bonnet valve 183a.Bonnett valve 183a is adapted to be mounted in a passage 183b extendingthrough a lug 183c formed integrally with valve upper section 38, whichextends completely through valve upper section 38. To provide hardwaterblending, a horizontal passage 183d is formed in valve upper section 38along the dashed lines shown in FIG. 3, to establish communicationbetween intake cavity 140 and vertical passage 183b in valve uppersection 38. Additionally, a passage 183e is formed in the upper portionof valve middle section 40, extending between the lower end of verticalpassage 183b and outlet passage 148 in valve middle section 40. Whenbonnet valve 183a is installed into vertical passage 183b, bonnet valve183a is manually adjustable to control the amount of hard water whichpasses directly from intake cavity 140 through vertical passage 183b andinto outlet passage 148 in valve middle section 40. This feature isadvantageous in some European markets, where it is desirable to provideservice water which is not completely soft by blending hard water withthe treated soft water.

Referring to FIG. 5, the mounting of drive assembly 102 to the uppersurface of valve upper section 38 is illustrated. As noted previously,drive assembly 102 comprises a motor 104 and a gear box 106, with adrive shaft 108 extending downwardly from gear box 106. A timing gear184 (FIGS. 5, 6) is keyed to Geneva drive shaft 94, and includes a pairof diametrically opposed drive tabs 186, 188 (FIG. 6). Drive tabs 186,188 are fixed in position relative to Geneva drive shaft 94 such thatdrive tabs 186, 188 are in vertical alignment with drive lugs 98, 100,respectively.

As noted previously, drive lugs 98, 100 of Geneva drive shaft 94 act toengage the Geneva cam surfaces 64 formed on rotor member 60. In thismanner, rotor member 60 is incrementally advanced about its axis ofrotation through a series of positions for selectively placing valveassembly 20 into a selected mode of operation. The movement of drivelugs 98, 100 is mirrored by drive tabs 186, 188 on timing gear 184,which engage a gear 190 which forms a part of actuator member 112.Referring to FIG. 5, actuator member 112 further comprises lower andupper cam actuator surfaces 192, 194, respectively, which are formedintegrally with gear 190. Lower actuator surface 194 is engagable with alower switch member 196 associated with switch assembly 114 (FIG. 6),and upper cam actuator surface 194 (FIG. 5) is engagable with an upperswitch member 198 associated with switch assembly 114. Switch assembly114 is wired into control board 30. The position of rotor member 60 isthus monitored by actuator member 112 in combination with switchassembly 114.

FIG. 7 illustrates in greater detail the driving engagement of Genevadrive shaft 94 with cam surfaces 64 provided on rotor member 60. WithGeneva drive shaft 94 in its position shown in FIG. 7, drive lug 100,which depends from lower plate 96 of Geneva drive shaft 94, is shown ina space defined by facing walls of adjacent cam surfaces 64. When Genevadrive shaft 94 is rotated in response to operation of motor 104 androtation of drive shaft 108, drive lug 100 rotates into contact with awall of one of the cam surfaces 64, for imparting rotary movement torotor member 60 and to cause rotor 60 to incrementally advance.Continued rotation of Geneva drive shaft 94 brings drive lug 98 into aspace between adjacent cam surfaces 64, for advancing rotor member 60another increment until the desired position of rotor member 60 isattained.

Referring still to FIG. 7, valve seat member 74 is illustrated aspositioned on top of flat upper surface 46 of valve middle section 40. Apair of diametrically opposed studs 198, 200 extend upwardly from uppersurface 46 of valve middle section 40. Studs 198, 200 are receivedwithin slots 202, 204, respectively formed in the outer edge of valveseat member 74 for maintaining valve seat member 74 in position relativeto valve middle section 40. Referring briefly to FIG. 2, it is seen thatvalve seat member 74 is provided with openings therethrough in locationswhich correspond to the locations of openings formed in the uppersurface of valve middle section 40, for providing fluid communicationinto and out of valve middle section 40.

Still referring to FIG. 7, plate-like lower portion 62 of rotor member60 is provided with an elongated opening 206. Referring momentarily toFIG. 3, opening 206 is employed to establish fluid communication betweeninlet cavity 140 in valve upper section 38 and one of the passagesformed in valve middle section 40 through valve seat member 74. Inaddition, an opening 208, shown in phantom at 208 in FIG. 7, is formedin the underside of plate-like lower portion 62 of rotor member 60. Apassage 210 extends between opening 208 and drain passage 68 formed instem 66 of rotor member 60. Referring again briefly to FIG. 3, passage68 in stem 66, in combination with passage 210 and opening 208,cooperate to define a flow path through rotor member 60 to providecommunication between drain opening 70 in valve upper section 48 and oneof the passages formed in valve middle section 40.

FIG. 8 illustrates the underside of valve rotor member 60 as constructedfor a downflow brining application. As shown, opening 206 opens into arecess 212 which faces toward the lower surface of lower portion 62.Similarly, opening 208 opens into a downwardly facing recess 214 formedin the lower surface of lower portion 62. Recesses 212, 214 act toestablish communication between passages in valve middle section 40 andpassages 206, 208, respectively, when rotor member 60 is in a positionin which openings 206, 208 are not directly aligned with the passages invalve middle section 40 with which they communicate.

For an upflow brining application, rotor member 60 is modified byextending recess 214 to encompass the area represented by phantom line215. This modification provides discharge of waste water from passage142 (FIG. 3) through valve seat member 74 in an upflow briningsituation.

FIGS. 9 and 10 illustrate brine valve assembly 116 in detail. Referringto FIG. 9, brine valve assembly 116 generally includes a one-piece brinevalve body 118, including a mounting flange 222 adapted for placementagainst a mounting surface formed on valve middle section 40. Brinevalve body 118 is mountable to valve middle section 40 by means of aseries of threaded fasteners extending through brine valve body 118 andcap member 139e into openings formed in the mounting surface of valvemiddle section 40.

As noted previously, brine valve body 118 includes a brine inlet nipple120 which is adapted for connection to the end of a line connected atits other end to the brine tank (not shown). A passage 226 is formed inthe interior of nipple 120 and check ring valve seat 139d which includesan opening 230 is placed against a shoulder at the inner end of brinepassage 226. A series of ribs, two of which are shown at 232, 234 extendlongitudinally within a check passage 235 to the left of the shoulder atthe inner end of passage 226, and check ball 139c is located in checkpassage 235. Check passage 235 communicates with an annular space 238located around the medial portion of injector member 124, throughopenings representatively illustrated at 240, 242. A rib, such as shownat 244, maintains check ball 139c in position within check passage 235.

As noted previously, a passage 126 is formed in the mounting surface ofvalve middle section 40, and the inner portion of injector member 124 islocated in passage 126. Referring briefly to FIG. 3, passage 126communicates with passage 162 formed in valve middle section 40, whichis selectively exposed to fluid pressure through rotation of rotormember 60. An inlet water passage 246 (FIG. 9) is formed in injectormember 124, leading to a restriction 248 which communicates betweenpassage 246 and brine inlet area 164. In a manner as is known, whenfluid pressure is supplied to inlet passage 246, restriction 248 createsa vacuum in brine inlet area 164 to unseat check ball 139c from opening230, and to allow flow of brine from brine passage 226 through checkpassage 235 and the openings in the end thereof, such as shown at 240,242, into brine inlet area 164. The mixed brine and intake water thenflows from brine inlet area 164 through a passage 250 having a diameterlarger than that of restriction 248, and from passage 250 to a passage252 formed in the end of injector member 124 opposite passage 246. Frompassage 252, the mixed brine and intake water flows to passage 154 (FIG.10), which unseats diaphragm check valve 134 and allows flow of mixedbrine and intake water into brine passage 163 in valve middle section 40(FIG. 3), and downwardly through the valve structure to the mineral bedto recharge the bed.

As also shown in FIG. 9, shaft 138 of the brine shuttle assembly islocated in brine inlet passage 226 between the legs of check valve seat139d. Shuttle assembly head 139a is located in passage 137, which is incommunication with treated water passage 132 (FIGS. 2, 3) and is therebyexposed to treated water pressure. An o-ring 255 is located against theinner shoulder formed by head 139a and shaft 138, and is adapted to seatagainst a shoulder formed at the inner end of passage 137. A series ofribs, such as shown at 256a and 256b, are formed in passage 137 adjacentthe shoulder. Shuttle assembly seat 139b is located in a passage 257formed in brine valve body 220, and an o-ring 258 is retained within agroove formed in seat 139b and is adapted to seat against a shoulderformed on the inner end of passage 257 to form a fluid-tight seal. Withthe illustrated arrangement, the shuttle assembly is reciprocablymovable between a closed position in which head 139a seats against theshoulder at the inner end of passage 137, as shown, and an open positionin which head 139a is moved away therefrom. The brine shuttle assemblyis caused to move to its open position by pressure in passage 257, whichresults from movement of rotor member 60 to the fast rinse/refillposition whereby water pressure is introduced into passage 130 (FIG. 2).The face of shuttle assembly seat 139b has an area greater than that ofshuttle assembly head 139a, and accordingly, the presence of pressure inpassage 257 unseats head 139a to establish communication between treatedwater passage 137 and brine passage 226. Treated water then flows frompassage 137 through brine passage 226 and the brine line into the brinetank. When passage 206 in rotor member 60 moves past the fastrinse/refill position to cut off the supply of water pressure in passage257 and the trailing drain opening passage 208 in rotor member 60 lowersthe pressure in passage 257, the pressure in passage 137 acts on theface of head 139a to once again seat head 139a against the shoulder atthe inner end of passage 137.

Reference is now made to FIGS. 11-14, which illustrate the variouspositions of openings 206, 208 in downflow rotor member 60 relative tothe top of valve seat member 74. In each figure, the top of seal plate74 is illustrated in solid lines, and the phantom lines indicateopenings 206, 208 in rotor member 60. In the 0° service position shownin FIG. 11, opening 206 in rotor member 60 is shown aligned with aservice port 260, which corresponds in location with the upper end ofpassage 142 (FIG. 3). In the service position, drain opening 208 isblocked. FIG. 12 illustrates rotor member 60 at a 120° position forbackwashing the mineral bed. In this position, pressurized fluid issupplied through opening 206 in rotor member 60 to a backwash port 262,which corresponds in location to the upper end of passage 155 (FIG. 3)in valve middle section 40. Intake hard water is also supplied throughopening 206 to hardwater bypass port 264, which corresponds in locationto the upper end of passage 149 (FIG. 3) in valve middle section 40.

Referring to FIG. 13, the openings in rotor member 60 are shown rotatedto the 180° brine/slow rinse position. In this position, drain opening208 in rotor member 60 is disposed over backwash port 262, which openspassage 155 (FIG. 4) to drain passage 68 in rotor member 60. In thisposition, inlet port 206 in rotor member 60 is located over hardwaterbypass port 264, and also over a brining port 266, which corresponds inlocation to the upper end of passage 162 (FIG. 3) in valve middlesection 40.

In FIG. 14, the openings in rotor member 60 are shown rotated 210°,which is the fast rinse position. In this position, rotor member drainopening 208 is in communication with hardwater bypass port 264. Inletopening 206 is positioned over brining port 266, and also over a rinseport 268, which corresponds in location to the upper end of passage 168(FIG. 3) in valve middle section 40.

FIGS. 15-18 illustrate in greater detail the construction of valve seatmember 74. FIG. 15 illustrates the top plan view of valve seat member74, while FIG. 16 represents its bottom plan view.

Referring to FIG. 15, valve seat member 74 generally comprises anannular reinforcing or stiffening ring, shown at 280. Ring 280 ispreferably formed of metal, and the remainder of valve seat member 74comprises a thermoplastic elastomeric material encapsulating reinforcingring 280. This material allows valve seat member 74 to be injectionmolded. The material of valve seat member 74 may advantageously beformed of a base resin of Monsanto "Santoprene", FDA grade 171-73.

A pair of annular raised ribs are formed on valve seat member 74, theouter of which is shown at 282 and the inner of which is shown at 284. Aseries of radial raised ribs extend between outer and inner ribs 282,284, and are shown at 286, 288, 290, 292, 294, 296, 298 and 300. Outerand inner ribs 282, 284, in combination with radial ribs 286-300, act tosurround ports 260, 262, 264, 266 and 268, to provide a fluid-tight sealbetween the upper surface of valve seat member 74 and the underside ofrotor member 60.

Referring to FIG. 16, the underside of valve seat member 74 is providedwith an inner annular rib 302 and an outer annular rib 304. A series ofradial ribs 306, 308, 310, 312, 314, 316, 318 and 320 extend betweeninner and outer annular ribs 302, 304. Ribs 302 and 304, in combinationwith radial ribs 306-320, act to surround openings 260-268 in valve seatmember 74 to provide a fluid-tight seal between the underside of valveseat member 74 and the upper surface of valve middle section 40.

Referring to FIGS. 17 and 18, the construction of ribs 314 and 316 onthe underside of valve seat member 74 is illustrated, as is theconstruction of ribs 292, 294 in the top side of valve seat member 74.Ribs 292, 294 and 314, 316 act in combination with the inner and outerannular ribs on the top and bottom surfaces of valve seat member 74 tosurround port 264. Ports 260, 262, 266 and 268 are enclosed in a similarmanner by the rib structures formed on the top and bottom surfaces ofvalve seat member 74.

As noted, valve seat member 74 is statically mounted to the uppersurface of valve middle section 40. Rib 314 comprises a double ribstructure including a rib 322 and a rib 324, with a depression 326located therebetween. Rib 316 on the other side of port 264 is similarlyconstructed, comprising a rib 328, a rib 330 and a depression 332located therebetween. When valve seat member 74 is sandwiched betweenthe underside of rotor member 60 and the upper surface of valve middlesection 40, ribs 322, 324, 328 and 330 are compressed so as to provide afluid-tight seal. When rotor member 60 is rotated so as to provide waterpressure to port 264, for example, the water pressure exerts a lateralforce on ribs 324 and 328. The construction of ribs 326 and 332 is suchthat the lateral force so exerted only serves to assist in sealingbetween ribs 324, 328 and the upper surface of valve middle section 40.The presence of the depressions 326, 332 between ribs 322, 324 and 328,330, respectively, allows lateral movement of the ribs when a lateralforce is exerted thereon by water pressure, to assist in sealing.

In some instances, a lateral force due to water pressure will be exertedin opposite directions on, a radial rib, e.g. rib 310 (FIG. 16) betweenports 266 and 268. Each radial rib being identical in construction toribs 314, 316 (FIG. 17), the depression between adjacent ribs allowslateral deflection of each rib in opposite directions to assist insealing.

The construction of inner and outer annular ribs 302, 304 on theunderside of valve seat member 74 is similar to that shown and describedin FIG. 17 with respect to radial ribs 314 and 316.

Referring again to FIG. 17, ribs 292 and 294 in the top side of valveseat member 74 will be described. As noted previously, rotor member 60(FIG. 2) is assembled to valve upper section 38, and a downward springforce is exerted on rotor member 60 by the wave spring washer 78disposed between rotor member 60 and valve upper section 38. In thismanner, a downward preloading force of approximately 120 pounds isexerted on rotor member 60, which bears against the ribs formed on thetop surface of valve seat member 74. Additionally, water pressure actingonthe top surface of rotor member 60 drives it against valve seat member74, to seat rotor member 60 against valve seat member 74, assisted bythe preloading on rotor member 60 by the spring.

Each of the radial ribs in the top side of valve seat member 74 isformed similarly to ribs 292 and 294, illustrated in FIG. 17. Referringto rib 292, each rib comprises a compound rib structure providing arelatively wide base rib 334 and a seal rib 336. Base rib 334 resiststhe compressive force exerted on valve seat member 74 by rotor member60, while seal rib 336 is deformed slightly under the compressive loadto provide a fluid-tight seal against the underside of rotor member 60.

Rotor member 60 rotates relative to valve seat member 74 in thedirection of the arrow 338 in FIG. 17. Each of radial ribs 286, 288,290, 292, 298 and 300 is constructed similarly to ribs 292 and 294 asillustrated in FIG. 17, in which the leading angled surface of seal rib338 is oriented toward the direction of rotation of rotor member 60. Inthis manner, as valve seat member 60 rotates on valve seat member 74,the seal ribs, such as 336, are uniformly compressed downwardly towardbase rib 334.

Referring to FIG. 18, outer and inner ribs 282, 284 on the top surfaceof valve seat member 74 are constructed similarly to ribs 292, 294,shown in FIG. 17 and described above. Outer rib 282 comprises a base rib340 and a seal rib 342, and inner rib 284 comprises a base rib 344 and aseal rib 346. The leading surfaces of seal ribs 342, 346 are oppositelyoriented.

Reference is now made to FIGS. 19-21, which illustrate an improvedbypass valve, shown generally at 350, usable in connection with valveassembly 20. Bypass valve 350 is connected to valve assembly 20 in placeof inlet/outlet member 138 (FIGS. 1 and 5). Bypass valve 350 is manuallyoperable for selectively routing water through valve assembly 20 and thewater conditioning system, or for bypassing the conditioning system andvalve assembly 20.

Bypass valve 350 generally includes a valve body 352 and a spool member354. Valve body 352 includes an inlet port 356 and an outlet port 358.When valve body 352 is connected to valve middle section 40 in place ofinlet/outlet assembly 138, inlet port 356 is in communication with inletport 58 in valve middle section 40, and outlet port 358 is incommunication with outlet port 59 in valve middle section 40.

Valve body 352 further includes an inlet nipple 360 connectable to thewater supply to valve assembly 20, and an outlet nipple 362 connectableto the water outlet line. Inlet nipple 360 includes an inlet passage364, and outlet nipple 362 includes an outlet passage 366. Inlet passage364 extends along a longitudinal axis which is in line with thelongitudinal axis of inlet port 356 and valve middle section inlet 58.Outlet passage 366 extends along a longitudinal axis in line with outletport 358 and valve middle section outlet 59.

Spool member 354 is mounted for sliding longitudinal movement within aspool passage 368 formed in bypass valve body 352. Spool member 354 ismovable between a bypass position shown in solid lines in FIG. 19, andan operating position shown in phantom in FIG. 19. Spool member 54generally includes a right-hand end portion 370 providing a plate 372 atits right end, and at its left end an o-ring seat 371 in which an o-ring374 is positioned. A shaft 376 extends from the left-side of o-ring seat371 and is connected at its left end to a sealing land 378. Land 378 isprovided with an o-ring seating area 380, and an o-ring 382 ispositioned within seating area 380. A shaft 384 extends leftwardly fromland 378, and terminates at its leftward end in a sealing land 386. Land386 is provided with an o-ring seating area 388, and an o-ring 390 ispositioned within seating area 388. A connecting portion 392 extendsbetween the leftward side of land 386 and an o-ring seat 394. An o-ring395 is positioned within o-ring seat 394. A left end portion 396 extendsleftwardly from o-ring seat 394, terminating in a plate 398. Plate 398has a diameter slightly less than the internal diameter of passage 368,which allows spool member 354 to be inserted in a right-to-leftdirection into passage 368.

Referring to FIG. 20, left end portion 396 of spool member 354 isprovided with a pair of ribs 400, 402. An internally threaded opening404 is formed in bypass valve body 352 toward the left end of passage368, and a threaded screw 406 extends through opening 404. Screw 406engages ribs 400, 402 to maintain proper angular orientation of spoolmember 354 within passage 368. Ribs 400, 402 extend between the leftwardsurface of o-ring seat 394 and the inner surface of plate 398, whichserve to define the extent of travel of spool member 354 within passage368 due to engagement of screw 406 therewith during leftward andrightward movement of spool member 354.

Spool member 354 can be removed from 368 by removing screw 406 fromopening 404 in valve body 352.

In operation, bypass valve 350 functions as follows. When spool member352 is in its bypass position shown in solid lines, intake waterentering valve body 352 through inlet passage 364 is prevented frompassing through passage 368 to inlet port 356, and is deflectedleftwardly, within passage 368 by land 378. The intake water is thendirected to outlet passage 366 by land 386. When spool member 354 ismoved leftwardly to its operative position, intake water enteringthrough inlet passage 364 passes over shaft 376 and enters inlet port356, for entry into valve assembly 20. Water output from valve assembly20 is supplied to outlet port 358, and is directed over shaft 384 tooutlet passage 366. When spool member 354 is in the operative position,a fluid-tight seal is provided for passage of intake water throughpassage 368 by o-rings 374 and 382. Fluid-tight passage of water fromoutlet port 358 to outlet passage 366 is provided by o-rings 382 and390. In the bypass position, o-rings 382 and 390 provide fluid-tightpassage of water directly from inlet passage 364 to outlet passage 366,and o-rings 374 and 395 seal inlet and outlet ports 356, 358,respectively, of valve assembly 20.

FIG. 21 illustrates land 386 and o-ring seat 394 in detail. As shown inFIG. 21, land 386 is provided with a curved convex-to-concave shape.When spool member 354 is in its bypass position in passage 368, land 386spans between the wall of passage 368 to the left of outlet passage 366and the wall of passage 368 to the right of the opening of outlet port358 into passage 368, to seal off any communication between outlet port358 and outlet passage 366. Land 378 is similarly constructed, so thatwhen spool member 354 is in its bypass position, communication betweeninlet passage 364 and inlet port 356 is cut off.

In the past, bypass valves have been constructed with inlet and outletpassages having a greater center-to-center spacing than the inlet andoutlet ports of the conditioner valve, requiring extensive modificationin the plumbing system to accommodate the increased center-to-centerspacing.

With the construction of bypass valve 350 as shown and described, bypassvalve 350 can be installed without extensive modifications to theplumbing which connects the water system to valve 20. This is providedby the center-to-center spacing between inlet passage 364 and outletpassage 366 being identical to the center-to-center spacing of the inletand outlet ports 356, 358, which is the same as the spacing of the inletand outlet passages in inlet/outlet member 138. In addition, bypassvalve 350 is capable of handling high rates of flow, due to the designof sealing lands 378, 386.

Various alternatives and embodiments are contemplated as being withinthe scope of the following claims particularly pointing out anddistinctly claiming the subject matter regarded as the invention.

I claim:
 1. In a water conditioner rotary valve including a valve bodyadapted for mounting to the open top of a mineral tank, the improvementcomprising:a rotor member movably mounted within the valve body, therotor member defining a substantially planar surface having one or moreflow control openings formed therein for controlling the flow of waterthrough passages formed in the valve body; and a system for providingrotation of the rotor member within the valve body, comprising a seriesof spaced Geneva cam surfaces on the rotor member, a Geneva drive shaftengagable with the cam surfaces and movably mounted to the valve body,and means for selectively imparting rotation to the Geneva drive shaft.2. The improvement of claim 1, wherein the Geneva drive shaft includesone or more drive lugs for engaging the Geneva cam surfaces and drivingthe rotor member in response to rotation of the Geneva drive shaft. 3.In a water conditioner rotary valve including a valve body adapted formounting to the open top of a mineral tank, and a rotor member movablymounted within the valve body for controlling the flow of water throughpassages formed in the valve body, a system for providing rotation ofthe rotor member within the valve body, comprising a series of spacedGeneva cam surfaces on the rotor member, a Geneva drive shaft engagablewith the cam surfaces and movably mounted to the valve body, means forselectively imparting rotation to the Geneva drive shaft, and a drainpassage formed in a substantially central stem extending upwardly fromthe Geneva cam surfaces, the drain passage being adapted forcommunication with a drain passage formed in the valve body.
 4. In awater conditioner rotary valve including a valve body adapted formounting to the open top of a mineral tank, and a rotor member movablymounted within the valve body for controlling the flow of water throughpassages formed in the valve body, a system for providing rotation ofthe rotor member within the valve body, comprising a series of spacedGeneva cam surfaces on the rotor member, a Geneva drive shaft engagablewith the cam surfaces and movably mounted to the valve body, and meansfor selectively imparting rotation to the Geneva drive shaft, whereinthe valve body comprises assembled upper, lower and middle valvesections, and wherein the rotor member is located in a downwardly facinginlet cavity formed in the upper valve section for controlling the flowof water from the intake cavity to the valve middle section.
 5. Thesystem of claim 4, further comprising a valve seat member locatedbetween the lower surface of the rotor member and the upper surface ofthe valve middle section, to provide a water-tight seal therebetween. 6.The system of claim 4, wherein the means for selectively impartingrotation to the rotor means includes a drive motor mounted to the valveupper section, and an output shaft drivingly coupled to the drive motorfor engaging the Geneva drive shaft to provide rotation thereto.
 7. Thesystem of claim 6, further comprising a cam actuator member mounted tothe valve upper section and including a gear portion, and wherein a gearis mounted to the output shaft and has ears corresponding in location tothe location of drive lugs provided on the Geneva drive shaft which areengagable with the Geneva cam surfaces, with the cam actuator memberbeing engagable with switch means interconnected with a control systemfor the rotary valve.